FRONT TURN SIGNAL RELOCATION KIT - Harley
Contents
1. ONE Figure 1 Harness Shield Removal 1of5 is00693 La o Y 8 et _ Gy Right side turn signal Jam nut Ball stud Ball stud clamp Retainer Lockwasher Rear view mirror stalk Acorn nut OO NOA ON Brake master cylinder housing is00694a Left side turn signal Jam nut Ball stud Ball stud clamp Ball receptacle Lockwasher Rear view mirror stalk Acorn nut 9 00 SO OT 0 N a Clutch hand lever bracket Figure 2 Right Side Turn Signal Removal 8 See Figure 2 Using 5 8 in and 1 2 in wrenches hold the right side ball stud clamp 4 and loosen the jam nut 2 9 Hold the retainer 5 with the 5 8 in wrench and remove the ball stud clamp from the retainer Discard the ball stud clamp 10 Remove and discard the ball stud 3 and jam nut from the right side turn signal 1 Remove the turn signal lamp and allow it to hang down taking care not to damage any surfaces 11 Remove the retainer 5 and lockwasher 6 from the rear view mirror stalk 7 Discard the lockwasher and retainer 12 See Figure 3 Hold the left side ball stud clamp 4 and loosen the jam nut 2 13 Remove the ball stud clamp from the ball receptacle 5 Discard the ball stud clamp Unscrew and discard the ball stud 3 and jam nut from the left side turn signal 1 Remove the turn signal lamp and allow it to hang down taking care not to damage any surfaces J04390 F2. taut and tighten the cap screw to 8 3 10 0 ft lbs 11 3 13 6 Nm The wires from the right side turn signal should now be toward the right side of the vehicle and the left side wires toward the left is04980 Figure 5 Routing the Wires 13 See Figure 4 Install the socket terminals from the the turn signal harnesses into the correct lamp side connector halves following the instructions in the appropriate Service Manual Unless noted differently on removal Left side white connector 11 a Black BK wire in cavity 1 b Violet V wire in cavity 2 c Blue BE wire if installed in cavity 3 Right side black connector 10 a Black BK wire in cavity 1 b Brown BN wire in cavity 2 c Blue wire BE if installed in cavity 3 14 See Figure 1 Feed the assembled right side turn signal connector from the outside through the grommet 4 in the right side of the frame behind the steering head Feed the assembled left side connector through the grommet in the left side of the frame 15 Connect the left and right connector halves to the same color mating connector halves coming from the frame 16 Temporarily install the main fuse following the instructions in the appropriate Service Manual J04390 17 Test the turn signals to ensure they function correctly WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding
3. 00251b 18 Remove the main fuse WARNING Be sure that steering is smooth and free without interfer ence Interference with steering could result in loss of vehicle control and death or serious injury 00371a Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops 19 Use cable straps from the kit as needed to secure the harnesses so they do not interfere with steering function or become entangled or pinched Secure any excess harness length with a cable strap so it can be stowed inside the steering head 20 Push the wire harness back up inside the frame behind the steering head Position the harness shield 1 to the underside of the top bar with the tabs 2 inside and push upward until the tabs engage the holes 3 on each side of the frame WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 21 Install the fuel tank and connect the fuel line following the instructions in the appropriate Service Manual 22 Install the main fuse 23 Install the seat following the instructions in the appropriate Service Manual WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 000
4. 70b 24 Adjust the mirrors for proper field of vision and tighten the acorn nuts to 12 ft lbs 16 Nm Check mirror adjustment and reposition if necessary 4of5 SERVICE PARTS is04977 Figure 6 Service Parts Front Turn Signal Relocation Kit Table 1 Service Parts Table Item Description Quantity Part Number Stalk front turn signal relocation right 68565 08 2 Stalk front turn signal relocation left 68567 08 3 Socket head cap screw 5 16 24 x 5 8 in Grade 8 2 2698A 4 Lock washer split 5 16 in 2 7042 5 Screw button head 2 926 6 Nut acorn 5 16 24 chrome 2 7720 7 Washer star lock 5 16 inch 7127 8 P clamp 0 31 nominal diameter 10059A 9 Cable strap 8 10065 J04390 5 of 5
5. cMOTOR HARLEY DAVIDSON WY J04390 INSTRUCTIONS REV 2007 11 13 FRONT TURN SIGNAL RELOCATION KIT GENERAL Kit Number 69433 08 Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 6 and Table 1 REMOVAL WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 1 Purge the high pressure fuel line and disconnect the fuel line following the instructions in the appropriate Service Manual WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 2 Remove the main fu
6. igure 3 Left Side Turn Signal Removal 14 Remove the acorn nut 8 ball receptacle and lockwasher 6 from the rear view mirror stalk 7 Discard the ball receptacle lockwasher and acorn nut NOTES FXD FXDC and FXDL models The turn signal wires are routed alongside the hand control wires through retainers fas tened to the outside of the handlebar FXDB models The turn signal wires are routed through grommets on the underside of the handlebar switch housings then inside a sleeve along with the hand control wires through retainers fastened to the outside of the handlebar FXDWG models The turn signal wires are routed through grommets on the underside of the handlebar switch housings then inside the handlebars ALL models To make removal easier a smooth tape such as electrical tape can be used to cover the socket terminals at the ends of the turn signal wires 15 Completely remove the turn signals and wires from the handlebar 2of5 Models with turn signal wires OUTSIDE the handlebar switch housings FXD FXDC and FXDL models While supporting the turn signal lamp pull the turn signal wires upward and outward through the wire retainers Set the signal lamps and wires aside for installation Models with turn signal wires INSIDE the handlebar switch housings FXDB and FXDWG models a Remove one of the handlebar switch housings from the handlebar following the instructions in the appropriate Service Manual Sup
7. port the hand lever to prevent damage b Separate the upper and lower switch housings fol lowing the instructions in the appropriate Service Manual Carefully cut and remove the cable strap inside the switch housing and identify the wires coming from the turn signal lamp not the turn signal switch on the handlebar control pod c Support the turn signal lamp and pull the turn signal wires upward and outward through the handlebar wire harness bundle until the turn signal wires are free of the others up to the switch housing grommet d Remove the tape used to cover the socket terminals at the ends of the turn signal wires Pull the wire har ness through the hole in the switch housing with the grommet e Remove the grommet from the turn signal wire har ness and install it back in the hole in the switch housing Set the signal lamp and wires aside for installation f Assemble the wire bundle to the metal bracket at the bottom of the housing using a new cable strap from the kit It may be necessary to use a T 15 TORX drive head to loosen the bracket to install the wire tie g Assemble the upper and lower switch housings fol lowing the instructions in the appropriate Service Manual Install the switch housing to the handlebar h Repeat for the opposite side switch housing INSTALLATION 1 ALL models See Figure 2 Fasten the mirror stalk to the front brake master cylinder housing 9 with the acorn nut 8 and lock
8. se following the instructions in the appropriate Service Manual w Remove the seat following the instructions in the appro priate Service Manual Save all seat mounting hardware NOTE When moving the fuel tank back do not damage the fuel gauge wires clipped to the frame under the left side of the fuel tank J04390 Remove the front and rear fuel tank mounting hardware following the instructions in the appropriate Service Manual Move the fuel tank back on the frame to gain access to the tabs on the steering head harness shield See Figure 1 Disengage the tabs 2 from the holes 3 on each side of the frame and remove the shield 1 Pull the wire harness down from inside the frame enough to disconnect the white left 31L and black right 31R 3 place turn signal connectors Set aside the frame side connector halves Remove the socket terminals from the lamp side connector halves following the instructions in the appropriate Service Manual Make note of the wire colors installed in the cavi ties of each connector which should be Left side white connector a Black BK wire in cavity 1 b Violet V wire in cavity 2 c Blue BE wire if installed in cavity 3 Right side black connector a Black BK wire in cavity 1 b Brown BN wire in cavity 2 c Blue wire BE if installed in cavity 3 is00692 N A NY ee E of Harness shield Harness shield tab 2 Hole in frame 2 Grommet 2
9. talk and thread the screw into the lamp housing Do not fully tighten at this time 5 Place the mounting bracket in position on the lower fork below the triple clamp 6 Align the lamp to face forward and parallel to the ground While holding the alignment remove the assembly and tighten the lamp mounting screw 4 to 70 80 in Ibs 8 9 Nm 6 Install the mounting bracket assembly to the lower fork with a pinch bolt 7 ensuring a That the lamp is facing forward and parallel to the ground b Verify that the exiting wire is centered in the wire notch 3 at the stalk base and is not being pinched by the stalk against the fork bracket 7 Tighten the pinch bolt 7 to 70 80 in Ibs 8 9 Nm 8 Repeat Steps 1 7 for the opposite side 9 Remove the cap screw and washer 8 that mount the front brake line s to the underside of the lower fork bracket and set aside 10 Loosely install the P clamp 9 and the brake line with the cap screw and washer 8 NOTE P clamp orientation should be opposite of the brake line mounting 3 of 5 11 See Figure 5 Route the wires behind the fork tubes Feed both signal wires through the P clamp in the direction opposite that from which they originated so the wire is heading back toward its own turn signal lamp NOTE Ensure the wires are not pulled tight when the handlebars are turned full to the left or right fork stops 12 Pull the wires through the P clamp so they are just pulled
10. washer 6 from the kit but do not fully tighten at this time 2 See Figure 3 Fasten the mirror stalk to the clutch hand lever bracket 9 with the acorn nut 8 and lockwasher 6 from the kit but do not fully tighten at this time NOTES See Figure 4 The mounting brackets are stamped with either LH left side or RH right side Be sure to install the correct bracket on the correct side Both left side and right side turn signal lamps are identical The wire harness exiting the turn signal lamp has a flat cross section similar to the wire slot 3 near the lamp end of the Stalk For best appearance align the harness along its full length to determine the flat side that will lie against the stalk when the J04390 lamp is attached Insert the harness into the slot in that orien tation to avoid a half twist in the wire harness at the lamp is04978 Left side turn signal Right side turn signal Wire slot 2 Cap screw 2 Lockwasher 2 Triple clamp partial view shown Pinch bolt 2 Cap screw and washer P clamp 10 Right side black connector PHMNOARYNS 11 Left side white connector Figure 4 Installation of Mounting Bracket and Wire Harness 3 Carefully feed the length of wire from the turn signal lamp into the stalk through the wire slot 3 4 Install the screw 4 and lockwasher 5 into the stalk and through the hole Position the turn signal lamp against the end of the s
Download Pdf Manuals
Related Search